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Safety, Operation and Maintenance Manual-September 30, 2019

feiyezhengmian

SR400R

Rotary Drilling Rig

Safety, Operation & Maintenance Manual

WARNING

Read and follow the safety precautions and instruction in this manual and on the machine

decals. Failure to do can cause serious injury, death or property damage. Keep this manual with

the machine for reading and future reference.

SR400R Rotary Drilling Rig

mengkf 2022-04-21

Main Page

Table of Contents11
Introduction21
Introduction22
Overview23
Your Documentation Package23
Organization of this Manual24
Your Sany Machine25
Special Tips25
Application of Rotary Drilling Rig26
Machine Directions26
Machine Information26
Product Nameplate27
Contact Information29
Safety31
Foreword35
Hazard Words35
Hazard Word Levels35
Safety35
Other Signal Words36
Safety and Informational Machine Decals37
Locations37
Meaning41
Safety Equipment54
Hydraulic Lock Lever54
Fire Extinguisher54
Emergency Exit55
Seat Belt55
Emergency Stop Button56
Limit Switches57
Safety Precautions58
Be Cautious of High Pressure Fluid58
Dust Hazard59
Mechanical Injury59
Battery Hazards61
Fire Prevention62
Away from Fire62
Daily Checks63
Fire Treatment64
Scald Prevention64
Safety Information of Hose65
Fluid Leakage66
Crawler Safety Information67
Lightening and Strong Wind Precautions68
Falling Protection68
Noise Protection69
Vibration69
Wire Rope Safety Information69
Climbing On/Off Drilling Rig70
Kelly Bar and Drilling Tools71
Working at Areas with Underground Pipelines71
Working at Areas with High Voltage Power Lines72
Electrical Accident73
Safety During Operation74
Personnel Requirements74
Personal Protective Equipment75
Keeping the Drilling Rig in Good Service Condition76
Safety on Construction Site77
Signals to Control Operation79
Drilling Rig Danger Area84
Avoiding Tipping85
Before Entering the Cab86
Before Starting the Engine87
Before Operating the Drilling Rig87
Drilling Rig Operation88
Construction of Drilling Rig89
Drilling Rig Dismantling90
Parking Safety91
Transporting Drilling Rig92
Drilling Rig Maintenance93
Winch Operation94
Maintenance Safety94
Maintenance Personnel94
Risks in Maintenance94
Preparing for Maintenance98
During Maintenance100
Environment Protection102
Proper Waste Disposal102
Mud Pollution102
Fuel Discharge103
System Function105
General Structure109
System Function109
Machine Description111
Traveling Mechanism111
Upper Carriage111
Hydraulic System112
Electrical System113
Main Winch114
Auxiliary Winch115
Mast116
Rotary Drive116
Kelly Bar117
General View of the Operator's Cab118
E-Pad119
Operation Control Panel121
Engine Ignition Switch and Engine Speed Control Dial123
Freewheel Pedal (Not Equipped in this Model)124
Air Conditioning System125
Control Panel125
Operation Method128
Radio137
Control Panel137
Radio Operation139
Traveling Lever/Pedal142
Left and Right Operation Handle143
Left Operation Handle143
Right Operation Handle143
Directional Function of Operation Handle144
Directional Function of Right Operation Handle145
Mast Lever145
Display147
Start-Up Interface147
Drilling Operation Interface148
Menu Interface152
Common Function - Function154
Common Function - Switch157
Common Function - Operation159
Common Function - Calibration162
Parameter Calibration Interface164
Locking Recess Parameter Calibration Interface166
Lubrication Operation Information Interface168
Lubrication Operation Information Interface - Parameter Setting169
GPS Status Interface170
GPS Unlock Interface171
Enter Information Interface172
Output Information Interface173
Maintenance Interface174
History Query Interface176
Ancient Fault Interface177
Overload Record Interface178
User Settings Interface179
Language Selection Interface180
Time Settings Interface181
Brightness Adjusting Interface182
Construction Method Interface183
Seat186
Level188
Alarm Lamp189
Electric Cabinet190
Hydraulic Cooling Fan Reverse Flow Button (Optional)191
Operation193
Operation194
Basic Operation199
Job Preparations199
Visual Checks199
Job Set-Up200
Checks before Starting the Engine202
Checking Coolant Level202
Checking Engine Oil Level202
Draining Water and Sediment in Fuel Tank202
Checking Fuel Amount and Refuel202
Checking Hydraulic Oil Level202
Oil Separator202
Checking the Electrical Circuit203
Checking Horn Function203
Starting the Engine204
Normal Start-Up204
Starting the Engine in Cold Weather206
After Starting the Engine206
Breaking in a New Machine206
Warming-Up Operation207
Shutting down the Engine208
Checks after each Workday210
Traveling210
Traveling Operation210
Traveling on Slopes214
Upper Carriage Swing216
Adjusting Drilling Center Distance217
Raising and Lowering the Mast219
Adjusting Mast to Verticality221
Crowd Control223
Main Winch Operation225
Auxiliary Winch Operation227
Rotary Drive Control229
Depth Measuring Control230
Calibration230
Depth Measurement Calibration230
Swing Angle Calibration232
Verticality Calibration233
Crawler Extending and Retracting234
Parking the Drilling Rig235
Regular Parking235
Checks During Parking236
Machine Locking237
Long-Term Storage237
Operation in Cold Weather239
Checks in Cold Weather239
Operation Tips in Cold Weather240
After Daily Operation242
After Cold Season243
Drilling Rig Construction243
Construction Preparation243
Drilling Rig Checks243
Drilling Tool Selection245
Drilling Rig in Place245
Drilling246
Drilling in Clay Layer246
Drilling in Sand Layer246
Drilling in Pebble Layer247
Drilling in Shale Layer247
Rigging & Derigging248
Requirements for Rigging and Derigging248
Guidelines for Rigging and Derigging248
Notes on Rigging and Derigging249
Preparation for Rigging and Derigging250
Rigging Drilling Rig250
Removing Locking Bar250
Extending the Crawlers251
Mounting Counterweight251
Fixing the Supporting Trestle253
Installing Middle Mast and Mast Cylinder255
Installing Main Winch258
Installing Upper Mast and Masthead258
Installing Wire Ropes260
Raising the Mast266
Mounting Rotary Drive267
Drilling Rig Test Run269
Installing Drilling Tool270
Connecting Rope Swivel to Kelly Bar270
Connecting Kelly Guide to Kelly Bar271
Aligning Drilling Rig with Kelly Bar Upper End272
Connecting Wire Rope and Rope Swivel272
Installing Kelly Bar273
Installing Drilling Bucket277
Disassembling Drilling Tool277
Disassembling Drilling Bucket277
Removing Kelly Bar278
Disassembling Drilling Rig280
Removing Rotary Drive280
Mast Forward Inclination282
Removing Main and Auxiliary Rope283
Removing Masthead and Upper Mast285
Removing Middle Mast and Mast Cylinder286
Removing Supporting Trestle288
Removing Counterweight289
Wire Rope290
Installing Wire Rope290
Unloading and Storing Wire Rope296
Discarding Wire Rope297
Drilling Rig Transport299
Transport Requirements299
Safety Guidelines for Transport299
Transport Parameters301
Transport Dimensions a (Without Rotary Drive, Upper Mast and Masthead)301
Transport Dimensions a301
Masthead)301
Transport Dimensions B (Without Rotary Drive, Upper Mast, Masthead and Counterweight)303
Transport Dimensions B303
And Counterweight)303
Transport Dimensions C (Without Rotary Drive, Mast Assembly, Counterweight and Main Winch)305
Transport Dimensions C305
Loading and Unloading the Machine309
Requirement for Loading and Unloading the Machine309
Loading the Machine309
Fastening Method312
Unloading the Machine312
Requirements for Sea Transportation312
Kelly Bar314
Instructions314
Welding315
Transport and Storage320
Drilling Tool322
Overview322
Kelly Box322
Drilling Tool Categories323
Drilling Bucket Double-Edge323
Cone Auger325
Straight Auger327
Core Barrel328
Double-Layer Core Barrel330
Underreamer Bit331
Casing Drive Adapter331
Easily Worn Parts of Drilling Rig332
Drilling Tool Operation332
Drilling Bucket332
Auger333
Core Barrel334
Belling Tool335
Maintenance337
Maintenance Precautions341
Maintenance341
Maintenance Information342
Lubrication Points342
Drilling Rig Oil346
Maintenance Schedule349
Maintenance Procedures363
Every 10 Service Hours363
Crawler Tension - Check and Adjust363
Hydraulic Cylinders- Check365
Gearbox Gear Oil Level- Check367
Shock Absorbing Device of Rotary Drive - Check and Replace368
Crawler Track - Visually Inspect370
Wire Rope - Inspect372
Wire Rope - Maintain373
Rope Swivel Flexibility - Check374
Rope Swivel - Check and Lubricate374
Engine Oil Level - Check and Refuel375
Water and Sediment in Fuel Tank - Drain376
Hydraulic Oil Level - Check377
Coolant Level - Check379
Fuel Amount - Check and Refuel380
Initial 50 Service Hours381
Engine Oil and Filter - Change and Replace381
Fuel Filter - Check and Replace384
Filter of Water Oil Separator - Replace385
Fuel Tank Strainer - Clean387
Every 50 Service Hour387
Winch Reducers Oil Level - Check387
Switches, Buttons and Operation Handles - Check388
Rope Hold-Down Rollers - Check388
Rotary Drive Mounting Bolts - Check389
Driver Strip - Check and Change390
Rotary Drive Sliding Strip - Check and Replace391
Crawler Track Mounting Bolts - Check392
Air Intake and Exhaust System - Visually Check393
Window Wiper - Check393
Window Washer - Check393
Kelly Guide Swing Bearing - Replace394
Impact Ring - Check and Replace395
Spring of Kelly Bar- Check and Replace396
Shock Absorber - Check397
Initial 250 Service Hours397
Winch Reducer Oil- Change397
Bolts Connecting Swing Bearing - Check398
Reducer Gear Oil - Change398
Every 250 Service Hours400
Wire Rope Sheaves - Check400
Rotary Drive Gear Oil - Check400
Hoses - Check and Replace400
Kelly Guide Sliding Strip - Check and Replace401
Initial 500 Service Hours401
Gearbox Gear Oil - Change401
Gear Oil for Swing Reducer - Change402
Travel Reducer Oil - Change403
Every 500 Service Hours404
Engine Crankcase Breather - Clean404
Kelly Bar Baffle - Check405
Kelly Bar Drive Gibs - Check406
Kelly Bar Tube - Check406
Kelly Bar Locking Recesses - Check407
Engine Oil and Filter - Change407
Bolts Connecting Swing Bearing - Check407
Fuel Filter - Replace407
Filter for Water Oil Separator - Replace407
Fuel Tank Strainer - Clean407
Gearbox Gear Oil - Change407
Winch Reducer Oil- Change408
Initial 1000 Service Hours408
Hydraulic Oil - Change408
Oil Suction Filter - Clean411
Every 1000 Service Hours411
Hydraulic Hose - Check411
Hydraulic Hose - Change412
Aux. Pump Filter Element - Change412
Pilot Filter Element - Replace413
Return Filter - Replace415
Battery - Clean and Recycle422
Air Recirculation Filter - Inspect and Replace423
Winch Reducer Oil - Change424
Gear Oil for Swing Reducer - Change424
Every 2000 Service Hours424
Oil Suction Filter - Clean424
Gearbox Gear Oil - Change424
Travel Reducer Oil - Change424
Hydraulic Oil - Change424
Storage of Drilling Rig424
Preparations before Storage424
Machine Storage425
Maintenance to the Drilling Rig During Storage425
Maintenance to the Drilling Rig be Fore Moving from the Warehouse426
Troubleshooting427
Troubleshooting428
Motor System - Troubleshooting429
Electrical System - Troubleshooting447
Hydraulic System - Troubleshooting449
Work Equipment - Troubleshooting455
Air Conditioning System - Troubleshooting467
Specifications469
Overall Dimensions471
Performance Parameters471
Specifications471
Wire Rope Specifications474
Kelly Bar Configuration475
Appendix477
Appendix478
Bolt Tightening Torque479
Common Misoperation481
Central Lubrication System483
Functional Description of the Central Lubrication System483
Components of the Central Lubrication System485
Method of Operation487
Troubleshooting490

SANY SR400R - Page 3

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